Over the last 40 years, the industry dealing with coil winders and coil winding processes has tremendously grown and extended its application areas. Coil winding can be defined as a process to make an electromagnetic coil with the help of a series of loops, which is used for a variety of applications in different industrial sectors. Ideally coil winders are used in components like relays, chokes, solenoids, transformers, resistors, inductors, electric motors and generators.

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ACE Equipment Company also offers PLC controlled coil winding machines which saves cost and time while performing complex coil windings.

 

 

One instrument that is a must in several enterprises and industries is the Coil Winding Machine. Let you know about Tesca Global&#;s Coil Winding Machine:

Coil Winding Machine: An Introduction

A coil winding machine is an apparatus referring to electrical engineering. It is also a prevalent instrument for the manufacturing of electromagnetic coils. Coil windings are useful as a circuit element to deliver a magnetic field to motors, transformers, and generators and is also a valuable tool for microphones and loudspeaker manufacturing. 

Winding machines come in shape and dimensions to complete any respective objective. The winding coil has parameters that impact the formats of the winding rings, which are: Q factor, Insulation strength, Inductance, and Strength of any desired magnetic field. 

Coil windings come into different groups depending on the geometry and type of coil windings. The device relies its electromagnetic coil abundance production upon automated mechanisms or varieties of equipment only.

What are the types of Winding Machine?

The winding coil is of different types depending on their manufacturing and mechanism of working, which are as follows:-

 After having a detailed study about the condition of the site, the user decides the appropriate winding machine. The machines are: 

1. Manual Motor Winding Machine

Manual Motor Coil Winding Machine is a category of tools used for manual winding of the coils on the stator and the rotor in generators, transformers, electric motors, and large capacitors. It is also sometimes used to wind cables around drums.

It is a type of coil winding machine that is useful for workshop Industries where the winding requirement is not that frequent compared to a larger scale industry. These machines are operated with hands and provide meticulous outcomes for coil loops.

2. CNC Linear/ Toroidal Winding Machine

CNC Linear/ Toroidal Winding Machine is valuable in winding conductors on a bobbin made of plastic, paper, or metal. It employs a persistent cross-tape to provide a coil of wire into a toroidal or linear-shaped core. 

These machines are practical tools in the electronics industry and many other sectors such as electrical motors, transformers, generators, electric vehicle batteries, and hybrid cars. It consists of a stationary axis and a rotating axis. The rotary axis holds the material wound onto the cable core, while the stationary axis winds it accurately. 

The primary purpose of these winding machines is to wind wire on the tube former mechanically. When it comes to a custom-made automated winding solution, this type of winding machine is helpful in locations where there is a requirement for such customization. It offers the feature for one of the coils or the undersized amount clusters of the Coil. If you enjoy a resolution for customized coils, then CNC windings are most reasonable in such terms.

3. Armature Winding Machine

An armature winding machine, a piece of equipment, works on electrical appliances&#; production. It has many characteristics, such as automatic feeding, automatic tensioning, and it can wind and unwind any altitude of wires. It takes the core, inserts it into a coil, and adds the necessary backing material to make it strong enough for use. 

The main work of this machine is the purpose of incorporating the loops on an electric motor to produce electrical power through induction. Many manufacturers use this device to make large quantities of electric motors, horizontally and vertically mounted in many industries, including automotive, construction machinery, aerospace, and mining equipment. 

It is a winding machine that enables standard and customized central field coil winding conditions. The device comes with hook commutators, and in some devices, it may also provide an auto wire cutting and hooking option.

4. Transformer Winding Machine

A transformer winding allows wind coils on a ferromagnetic core to assemble transformers. It is known for creating a secondary winding for an electrical transformer. It is a valuable tool when it comes to constructing high-voltage transformers.

The device dispatches electricity over prolonged lengths. The number of turns in each coil decides how much strength can be assigned safely over a provided term. These machines are usually automatic and can be computer-controlled and helpful in manufacturing power transformers, distribution transformers, power reactor/converter stations, and switchgear.

It is a device that is known for its robustness and flexibility. It offers winding capability of different sizes and shapes for the Transformers. Transformer coil winding machines are best for approaching places that are not accessible due to any condition related to the site.

5. Ceiling Fan

The winding machine is an essential part of the fan coil manufacturing industry, allowing manufacturers to create high-quality coils that are useful in various industries. It is a device helpful in repairing the starter inside a machine.

The issue with the machine is that it will burn the starter inside the machine if we use it excessively or if there is any other technical issue. 

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A) Hand Ceiling Fan Winding Machine

A Hand ceiling fan winding apparatus is beneficial in the rewinding procedure, and the process requires hand or manual involvement. The price of the fan winding machine is roughly INR 10,000 to 15,000, relying on the product and label.

B) Semi-Automatic Ceiling Fan Winding Machine

A semi-automatic ceiling fan winding machine is better than a hand ceiling fan machine, and it involves machinery that automatically handles the reminding process with some involvement. The price of a semi-automatic ceiling fan winding machine is around INR to , depending on the product and brand.

C) Fully Automatic Ceiling Fan Winding Machine

A fully automatic ceiling fan winding machine is a spiral technique that doesn&#;t mandate any involvement and meets the winding procedure automatically. It is a popular and valuable machine in industries. The price of the fully automatic ceiling fan winding machine is around INR to 40,000, depending on the product and brand.

Working Principle of Coil Winding Machine:

It is conducive if we know about the principle of coil winding machines to learn about it better. When we talk about the principles of this application, then minimizing the materials and volume and efficient coil is of utmost importance.

In the device, it is a fill factor that indicates the ratio of the area of the electrical conductors in the winding space. It requires rectangular flat wires for the fill factors as the round ones are often gaps. 

In this procedure, it requires to hold a high fill factor with basic and Packaging of wire so that it can reduce the air space. It increases the efficiency of any electrical instrument and enhances heat conductivity.

In the multilayer machine, the bottom wires in the upper layer molded in the lower layer levels for about 300 degrees clipped the coil. The wires in the Ortho cyclic winding are filled densely. And in the wild winding, it remains as a friend of a structure within the given space of the winding.

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Wild Winding:

When we talk about winding, then in this type of wherein the random wire places directs to a wider dispersal which results in the wire length on the coil body. It indicates why wires&#; dispersal leads to a wide spectrum of electric ring resistances.

It is a popular device for mass production, and it doesn&#;t have a high demand for machinery and operators that require high speed as their chances of damage. This type of wiring is applied to applications such as ignition coils, relay coils, small transformers, small electrical Motors, and devices that don&#;t have large wherein the gauges as it is best for works for gauges that are up to 0.05 mm.

Helical Winding:

When we talk about the spiral binding method of wiring, the wiring is placed in a spiral way in every layer of the machinery. The direction of the moment changes from layer to layer, and often, these wires are found crossing the layers underneath within the given space. In this, a wire compass, the descending layer never brings extant. If the device&#;s layer is accessed, it becomes tough for the structure to maintain, and it may also create a wild winding.

Orthocyclic Winding:

An Orthocyclic winding, a type of winding, constructs an optimal factor. It is best for the round wires in which the winding of the upper layer is placed within groups, and it is available with the help of the lower layer. 

It is a process that helps position the wire in parallel to the coil linkage, which positions around the coil body. The process requires the arranged wire to step with the proportions of the earlier wire gauge. The wire inhabits a spot after 60 degrees of the coil conference. It happened with the round coin, and the coil takes one side of the rectangular coil, and the winding step depends on the coil geometry and wire gauge.

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Process of Winding:

Let us focus now on &#;how is winding done.&#; Some of the processes that are involved in the overall process of winding are:

1. Linear Winding:

It is a technique in which the winding production takes place with spiralling the wire on a coil constructing appliance, component, a rotating coil body, and coil carrying. The wire comes from a supplier roll, and it contains around 400 kg of copper wire that is enamelled and filled with the help of a guiding tube before starting the whole process of winding the wire mounts on coils to clamp the device.

The element gets retained to disperse the guiding two utilizing a twisted slot on the coil with the linear laying action or movement. The apparatus accomplishes the rotary action with the help of computer-controlled Engines. The transverse axis of the wire assists the tube from one cycle to the rotation axis as per the wire&#;s diameter.

It estimates the coiling diameter. It takes place to get the pace during the complete winding procedure. The process scales the segments required to curl on the spiral device, and it combines with drive and spindles that support generating the turning action. With the help of the rotational axis and transverse axis, it operates in secret, synchronizing the whole winding process to bring the wire into the winding area evenly.

2. Flyer Winding:

In this method, dispersal is created with the assistance of a feeding wire/roll/nozzle presented to a flyer. It pivots at a specific space from the coil, and the wire feeds with the assistance of a flyer shaft. The winding process requires components fixed at the inside of the flyer; it is known as mandatory when fixing the wires outside the flyer.

It requires a successive winding method for the fixation of the wire for the rotating indexing tables. It includes wire clips of wire deflection and the circumference of the table. It enables a force along and fixation. With the help of this method, it permits the component to adjust, which permits it to diverge the deposition of the wire in the device&#;s wire clip.

3.  Needle Winding Technology:

It is a winding technology advantageous in curling the pole shoes critical to commuting the multiple three-phase Machines. These motors are shielded with insulation that sustains the course of the turn with the needle winding technique. A needle with a nozzle is found at the right angle to the movement.

It then travels in a lifting motion and through the stator packs with the help of the groove channel and goes straight or with the two adjacent poles of the engine to enable the wire to the preferred place. It then rotates at a turnaround pinpoint of the winding with the assistance of one tooth pitch. It occurs to retain the prior rotation output in reverse order.

It creates a layer arrangement, and when it comes to drawbacks of this technology, it drives support between two bordering poles with the extent of nozzle diameter. The size of the nozzle is around the diameter of the winding wire, so it doesn&#;t fill the space between the two adjacent poles.

4. Toroidal Core Winding Technology:

In this winding process, the magnetic core braces on the holding spout two functions slow Rotary movement along with the three rubberized moments of connection.  

It arranges to store ring orbital wheel at 90 degrees to the magnetic core, which comes at the circumference and introduces it to the epicenter of the magnetic/toroidal core&#;the wire coils roughly the storage ring of the wires so that they can shut again.

The end of the wire from the accumulator fixes to the core. It takes place as per the required amount in the wire accumulated to create the wounds for the toroidal core.

It produces a winding process that distributes alongside the circumference of the toroidal core with the support of the course of the wire accumulator ring and the toroidal core. It needs the accumulator to open again to release the wound toroidal core after the fulfilment of the procedure. The machines in this technology are partly automated as the wires are not fixable in the toroidal core from the start.

What are the types of winding in a transformer?

Layer windings:

In this winding, the insulated conductors are arranged axially around the windings. Moreover, the device also places the turns next to each other. It comes in single and multi-layered forms wherein the single-layered winding machine winds only one turn around the core limb. On the other hand, the multi-layered binding can turn insulated conductors around the wound into several layers. 

The insulated conductors separate from each layer by using oil ducts, solid insulation, and sometimes using both types of elements to separate the conductors. Whether it is a small and medium-sized transformer, this instrument is beneficial for both.

Helical winding or spiral winding:

It is a multi-layered winding tool with several conductors when we talk about winding. The conductors in this device are parallel, and also form single turns that wound along the axial direction. It places the wounds with spacers that come between the adjacent turns.

It has a resemblance to a corkscrew when it comes to construction. These devices are helpful even in low voltage and high currents. As current flows within the parallel conductors, the voltage remains the same in each turn.

However, the magnetic field at Parallel Conductor links may not remain the same as it distributes flux evenly between the conductors. The device then goes on ascending the uneven currents in the conductors. We can use the transportation technique in this device by equalizing the magnetic field by Linking each conductor to minimize the currents in the conductors. These devices are known for their robustness and significant factor.

Also Read about Tesca Global&#;s Frequency Counter.

Disc winding:

It is a transformer coil winding machine with several connected discs of conductors. The disc in this device winds multiple turns of insulated conductors that connect in a series to form a disc winding. With the help of spacers, the disc diverges from the adjacent disc&#;the disc, setup by looping single and several parallel conductors.

When we talk about the difference between helical winding and disc winding, helical windings only have one turn for every disk in the Parallel Conductor. In this winding, there are several turns in each disc. The Disc type windings that the Transformers require are above 25 KV. These devices are known for their robustness.

Foil windings:

Foil winding is a type of Transformer winding machine with the exterior of copper or aluminum sheets. These sheets spiraled numerous times to form multiple-layer windings in a spiral formation. This type of device helps support the high capacity Transformers in which the current ranges from 12 to 600 A. It includes the windings using single and multiple sheets in the parallel wound.

The foil winding machines help wind many long continuous conductive wires on a bobbin. These conductors are then used to make the various inductor coils required to construct transformers, reactors, and many other electrical pieces of equipment.

Coil Winding Machine Manufacturers:

Are you searching for a brand that offers top-notch quality equipment? If yes, then Tesca Global is the one you should go for without any doubt. Tesca Global is a professional manufacturer of winding machines, and Tesca Global focuses on developing more efficient products while maintaining our high-quality standards. The company has been dedicated to manufacturing and designing high-quality, affordable winders for all coil types and materials. 

The products cover single layer through triple layer machines for various applications in many industries. Some of the equipment so that the company offers are: 

Automatic Coil Winding Machine: 

The device comes with specifications such as:

• It has two spindle side loading types.
• It has a 0 to 99.9mm Winding Width.
• It has 300 rpm to rpm winding speed
• It comes with a 75mm Diameter Bobbin Swing 
• It has a Wire Gauge f 45 SWG to 25 SWG
• It has H.S.S. Lead staple. It comes with a box nut of 10mm pitch Traverse type.
• Manual Coil Winding Machine: The instrument presents specifications such as: 
• It is a Manual winding machine with a 1 no. 5 digit counter. 
• It has 200 mm, Max. Coil diameter. 
• The device has 120 mm, Max. Center distance.
• The device has 100mm, Max. Center height.

Manual Coil Winding Machine With Reel Carrier:

The device offers specifications such as:

• It is a mechanical counter with an automatic traverse unit.

• Wire range: 18 to 46 SWG.
• It has a 200 mm Max. Coil diameter.
• The device has 100 mm, Max. Center height.
• It has 120 mm, Max. Center distance.

Other than that, Tesca Global also offers different types of pieces of equipment such as Ceiling fan winding machine, motor winding machine, toroidal winding machine, thread winding machine, automatic coil winding machine, capacitor winding machine, filament winding machine, sewing thread winding machine India, cheese winding machine India, yarn winding machine, stator winding machine, linear coil winding machine, etc.

In the end, it is right to say that when it comes to transferring industry, then the one equipment that is of utmost importance is the coil winders. If you want to buy a coil winding machine, you should consider that good equipment research doesn&#;t do any harm. So do your research about the equipment brand features that different suppliers offer before buying the equipment. A robust and high-quality product is a good investment for your industrial application.

F.A.Q.s:

Which machine is used for spinning?

A winding machine is helpful for the spinning purpose not only for the function of winding but also to remove any fault in the system. 

It is a machine that winds strands of metal wire into coils or bundles. The most common winding machines help wind coils of steel and copper wire. These machines use gears, a motor, and an electronic servo controller to control the engine&#;s speed and the angle at which it turns.

What is the difference between coil and winding?

When we talk about getting enough knowledge about circuits, one thing that confuses people is the terms coil and winding. Let us briefly know the significant difference between coil and winding in the transformer. 

Oil is a winding of fire in a ring found in inductor transformers, ring antenna, and motor applications. The circuit is an inductor in this device, and the conductors are insulated. It comes with a hollow insulated pipe containing an iron or magnetic power Core. It divides inductance into two variables: inductance and fixed inductance. The application of this device is patch coil, close magnetic circuit, high current powder inductance, fixed coil radiofrequency inductance, etc. 

The winding in a transformer is a group of turns forming in an electric circuit corresponding to a voltage value. It offers different turns with each side of the winding, leading to Terminal voltage each time. It supplies power to several electrical types of equipment comprising different voltages in the multi-winding type of the winding device, and it comes with functions such as frequency selection and chokes action.

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